Abstract: An automotive headliner assembly includes a substrate that is configured to mount to a vehicle in a position generally covering a lower surface of a passenger compartment roof. Cavities are formed into the substrate between the upper substrate surface and the lower substrate surface to provide receptacles for electrical wiring, fiber optic cabling, EA foam and the like or to form a duct for directing air flow. Each of the cavities is integrally formed in the substrate. A foam layer is adhered to a lower surface of the substrate and the decorative cover is adhered to a lower surface of the foam layer. The headliner is constructed by first extruding molten parison into a blow mold shaped to complement the desired exterior contours of the headliner substrate to be formed. The cavities are then formed in the molten parison by inserting at least one blow pin into the parison and injecting pressurized gas.

Abstract: Spherical particles having a diameter between 0.007″ and 0.040″ are formed from melt extruded thermo-plastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040″ that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermo-plastic, plasticizers and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle; providing a heated casting surface and distributing a predetermined charge of such microspheres against the heated casting surface; melting the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: An apparatus for slush molding a thin shell having an outer layer and an inner layer. The apparatus includes two tubs alternately movable to a cast position for dispensing their respective material contents into a mold cavity. According to another embodiment of the invention, the apparatus includes a diverter valve configured to alternately open a passage from each of two tubs to the mold cavity to selectively dispense charge materials from the respective tubs into the mold cavity. In addition, a method is provided for forming a thin shell having an outer layer and an inner layer. A first polymer material is cast and allowed to melt on a heated mold surface to form an outer layer. A second polymer material is then cast and allowed to melt and form an inner layer on the inner surface of the outer layer. The shell is then removed from the mold.

Abstract: A fuel tank for a motor vehicle comprises at least one fuel filling opening, at least one fuel delivery pump, at least one operational vent means and at least one refuelling vent valve. The vent means and vent valve are connected to a fuel vapor filter by way of at least one vent conduit. At least one bead removal container is connected on the upstream side of the fuel vapor filter. At least the bead removal container and the refuelling vent valve are combined to form a functional unit in the form of a vent unit adapted to fit into an opening through the wall of the tank.

Abstract: An apparatus for monitoring the assembling, testing, and inspection of a product is provided comprising a plurality of kits, wherein each kit contains a plurality of parts to be assembled together to form a product. The apparatus further comprises a plurality of cue cards with each card having a status indicator corresponding to the assembly progress of a particular kit. A display device is further provided to visually display the plurality of cue cards. The status indicator of each cue card can indicate to load the parts into the kits, that the parts are ready to be assembled, that the parts are being assembled, and that the parts in the kit are assembled. A movable indicator, such as a pin, is movable between the status positions to visually indicate the same. The cue card further includes a priority level indicator that corresponds to the priority level of a particular kit.

Abstract: An airbag door system is provided comprising a substrate, an outer shell and a foam where all three layers possess a line of mechanical weakness with each line of mechanical weakness at least partially separating each layer into an airbag door portion and a trim member portion. The substrate line of mechanical weakness comprises at least one substrate aperture. The outer shell line of mechanical weakness comprises an outer shell reduced thickness portion defined by an outer shell sever extending partially through an outer shell thickness from an outer shell lower surface towards an outer shell upper surface. The foam line of mechanical weakness comprises a foam reduced thickness portion defined by a foam sever extending partially through a foam thickness from a foam lower surface towards a foam upper surface. The outer shell line of mechanical weakness is displaced relative to a foam line of mechanical weakness.

Abstract: A hydraulic warming system for low ambient temperature (0° to −65° F.) operation includes a hydraulic motor integrated in a valve manifold and driven by a two-stage jet pipe flow control electro-hydraulic servovalve mounted on the valve manifold in proximity thereof via a multi-port lapped spool-sleeve bypass-shutoff valve having a pre-loaded return spring. The spool is driven by a solenoid valve mounted on the valve manifold and coupled to the bypass-shutoff valve thereto between a first position and a second position. The first position utilizes the warmed low flow rate hydraulic leakage fluid from the servovalve to provide continuous warming of the internal rotating components of the hydraulic motor when the hydraulic motor is not operational. The second position includes diverting the warmed low flow rate hydraulic leakage fluid from the servovalve directly to hydraulic system return bypassing the internal rotating components of the hydraulic motor when the hydraulic motor is operational.

Abstract: A method of blind riveting to secure together a plurality of members (26, 27, 28) with aligned apertures, using a blind rivet comprising a tubular shell (11) with a head (13) and a stem (12) extending through the tubular shell. The method comprises the steps of: inserting the shell through the aligned apertures, from the near face of the near member, so that the remote end of the shell protrude beyond the remote face of the remote member and the nearest end of the shell is substantially level with the near face of the near member; supporting the near end of the shell while pulling the stem head to form a remote blind head; applying a force to the near member with respect to the stem, until any gap (28) between the members is taken up and deforming the now protruding portion of the shell to form a near-side head of the rivet. The invention also encompasses a blind riveting apparatus and blind rivets for carrying out the method described above.

Abstract: In an apparatus and method for remote ultrasonic determination of thin material properties using signal correlation, a method and apparatus are provided by which an arbitrarily-oriented anisotropic thin material may be interrogated for characterizing an unknown material property value thereof. The unknown material property may comprise for example temperature, pressure, elastic constants, density, hardness, composition, crystal orientation, grain size, and residual stress, or any material property that is variable with respect to known physical parameters of the material, for example known material elastic constants and/or density. In a first embodiment, theoretical signals are generated, for example a theoretical signal matrix, to characterize a material property value of a thin anisotropic material. A model of the thin material is generated comprising the behavior of the known material physical properties as functions of the unknown material property value to be characterized.

Abstract: An instrument panel of an automotive vehicle includes a rigid retainer preformed with an air bag opening and a recessed ledge extending about the opening. A separately formed door is installed on the opening and hinged to the retainer along one edge. The remaining three edges overlie the ledge to prevent inward movement of the door. The retainer and door are placed in a cavity of a mold tool in spaced relation to an outer skin and foam constituents are reacted therebetween to develop a foam layer. A foam seal is provided at the interface of the ledge and door to prevent the escape of foam past the ledge.

Abstract: A device for cutting a welded wire structure is provided. The welded wire structure includes a first wire and a second wire which are joined together and are offset relative to each other. The device includes a first arm pivotally connected to a second arm. The first arm includes a handle and a jaw connected thereto. The second arm includes a handle and a jaw connected thereto. The jaws are offset from each other. The jaw of the first arm includes a U-shaped portion into which the first wire is capable of being positioned during cutting. The jaw of the second arm includes a notch provided in a surface thereof which faces the jaw of the first arm. The second wire is capable of being positioned within the notch during cutting.

Abstract: An edge member for use on a composite flexure having an exposed edge surface. The edge member includes an innermost composite ply attached to the edge surface, an outermost composite ply attached to the innermost composite ply, and at least one interior composite ply disposed between the innermost composite ply and the outermost composite ply.

Abstract: A bulb shield for use in an automotive headlamp assembly, and a method for making same. The bulb shield includes a cup portion and a portion which extends from the cup portion and is configured for mounting to a reflector of the automotive headlamp assembly or to another, proximate structure. When the bulb shield is mounted, the cup portion is preferably generally horizontally aligned with a headlamp bulb in the automotive headlamp assembly, thereby eliminating a “hot spot” which would otherwise be viewable when looking into the headlamp beam. Preferably, at least a portion of the cup portion of the bulb shield is electro-formed. Such a bulb shield is relatively inexpensive and easy to make, yet can withstand the high temperatures which are typically experienced in an automotive headlamp assembly. Additionally, such a bulb shield can be inexpensively provided, yet meet precision requirements.

Abstract: A vehicle interior trim panel and method of making is provided where the vehicle interior trim panel comprises a skin, a substrate, a foam located between the skin and the substrate, and a flat wire at least partially surrounded by and embedded in the foam.

Abstract: A passive ranging system measured spectra of solar radiation off an adjacent spot and a distal target. Reflected solar radiation and differential attenuation are used to estimate target range. A comparison of absorption spectra from the solar illuminated distal target compared to the adjacent location is performed. Since the sun's position is always known, the increased absorption due to a distant target is derived from the differential between the adjacent spot and the distal target.

Abstract: The present invention is for an improved rotating control system for use on tilt rotor aircraft and helicopters. Existing rotating control systems usually include a non-rotating swashplate and a rotating swashplate, both swashplates having a plurality of clevises, each clevis formed by at least two clevis arms. The clevis arms are disposed in a clevis plane, and an axis of symmetry is located in the clevis plane between the clevis arms. The devises on the non-rotating swashplate are adapted to pivotally receive an actuator rod which has a rod axis defined by the actuator rod. The apparatus of the present invention includes an anti-rotation clip that is disposed between the clevis arms of each clevis of the non-rotating swashplate. The anti-rotation clip is either of unitary or multi-piece construction. The anti-rotation clip includes a wall portion and at least one restraining member that protrudes inwardly from the wall portion.

Abstract: A motor vehicle lighting device is provided comprising a ground illumination portion configured to direct a portion of the light emitted from a light source to illuminate a ground surface area rearward from the motor vehicle and a reverse signaling portion configured to direct a portion of the light emitted from the light source to an area different than the ground illumination portion. In this manner, a rearward vehicle lighting device designed for ground illumination and reverse signaling is provided from a single lamp and more preferably, using a single light source.

Abstract: A metallized composite includes a thermoplastic sheet and at least one discontinuous layer of metal within the thermoplastic sheet. The discontinuous metal layer can be disposed between two thermoplastic layers that are bound together, such as by melting the layers together, pressing, or by use of an adhesive. The metallized composites of the invention can be employed as reflective surfaces, such as are used as mirrors or substitutes for chrome trim on automobiles. A particularly preferred metal as a component of the discontinuous layer of the composite is indium.

Abstract: A process for manufacturing a metallized substrate using the island coating method, includes depositing a coating layer containing a radiation curable non-volatile film former. The coated part is then vacuum metallized to form the metal islands of the present invention. A layer of clear resinous protective dielectric topcoat containing a radiation curable non-volatile film former is then deposited to completely cover the layer of metal islands while maintaining the aesthetic properties of the metallizing island coating system at a reduced cost and with minimal variability among parts.